Customized 3D-Printed Wrist-Thumb Orthoses for De Quervain's Tenosynovitis: A Prospective Observational Study

Background: Wrist-thumb orthoses are commonly used in the conservative management of De Quervain's tenosynovitis; however, conventional fabrication techniques often limit anatomical fit and patient comfort. Three-dimensional (3D) printing enables patient-specific orthosis design and may improve usability, particularly in resource-limited rehabilitation settings. Objective: To evaluate the feasibility, clinical outcomes, and patient satisfaction associated with customized 3D-printed wrist-thumb orthoses in individuals with De Quervain's tenosynovitis. Methods: This prospective observational study included 40 patients with clinically diagnosed De Quervain's tenosynovitis, of whom 37 completed a six-week follow-up. Participants received either a conventional thumb spica splint or a customized 3D-printed wrist-thumb orthosis based on feasibility and availability. Pain intensity and upper limb functional status were evaluated using the Visual Analogue Scale (VAS) and the Quick Disabilities of the Arm, Shoulder and Hand (QuickDASH) instrument at baseline, two weeks, four weeks, and six weeks. Satisfaction with the 3D-printed orthosis was measured using the Quebec User Evaluation of Satisfaction with Assistive Technology (QUEST 2.0; MARCH Laboratory (Modeling for Assistive Technology and Community Living), Centre for Interdisciplinary Research in Rehabilitation of Greater Montreal (CRIR), Montreal, Quebec, Canada). Only descriptive statistical analyses were performed. Results: Both groups demonstrated substantial reductions in pain and functional disability over time. In the conventional group, mean VAS decreased from 81.25 at baseline to 14.32 at six weeks, while QuickDASH improved from 76.25 to 16.84. In the 3D-printed group, mean VAS decreased from 75.60 to 10.07, and QuickDASH improved from 72.15 to 11.34 over the same period. Numerically greater improvements were observed in the 3D-printed group. QUEST scores ranged from 3.0 to 4.5, indicating high levels of patient satisfaction. No device-related adverse events were reported. Conclusion: Customized 3D-printed wrist-thumb orthoses are feasible and associated with improvements in pain, functional outcomes, and patient satisfaction in patients with De Quervain's tenosynovitis. Findings should be interpreted as descriptive trends, and further studies with larger samples and inferential analyses are warranted. Keywords: 3d printing; de quervain’s tenosynovitis; patient satisfaction; rehabilitation medicine; wrist-thumb orthosis.